Minimizing deformation of a thin fluid film driven by fluxes of momentum and heat.

We consider a thin fluid film flowing down an inclined substrate subjected to localized external sources of momentum and heat flux that induce deformations of the fluid's free surface. This scenario is encountered in several industrial processes and of particular interest is the case where these deformations are undesirable. When the substrate is thin and the temperature along its underside is freely imposed by an active cooling mechanism, temperature gradients are generated at the fluid surface which drive a thermocapillary flow and influence the deformations. This naturally leads us to pose the optimal control problem of choosing the temperature profile that minimizes the unwanted free-surface deformations. Numerical computations reveal that the external forces generate deflections in a region near their peak beyond which all deflections are suppressed by the optimal control. Where nonzero deflections occur, the control is of bang-bang type (taking either its upper or lower bound), while the control is obtained in closed form for regions where the deflections are suppressed. Strikingly, in switching between these regions the optimal control chatters, that is, it switches infinitely many times over a finite interval. By appealing to Pontryagin's maximum principle and leveraging a symmetry embedded in the adjoint problem we uncover the underlying fractal structure of the chattering. Finally, we present practical approaches to avoid the infinite switching while retaining significantly reduced free-surface deformations.